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H14W User`s Manual
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2. Oil Suction Strainer Approx 250 microns 0 010 Return Line Filter rating 10 40 microns 0 0004 0 0016 GENERAL SPECIFICATION DATA 02 2 HYDRAULIC SYSTEM INSTALLATION INSTALLATION A IMPORTANT It is vital to ensure that all hose lengths are kept to a minimum Pressure and flow loss is increased as hose length increases and or bore size decreases Pressure and return lines in excess of 3 5 metres 11 5 should be compensated with an increase in nominal bore size As a general rule Bigger Nominal Bore Hose Better Winch Performance In all installation work on a hydraulic system cleanliness and accuracy are essential so that the hydraulic system functions properly HYDRAULIC PUMP SUCTION STRAINER RETURN FILTER HYDRAULIC OIL TANK 03 1 HYDRAULIC SYSTEM INSTALLATION MOUNTING It is important that the winch is mounted securely so that the motor mounting drum and wormbox housing are accurately aligned The tie bars supplied with the winch must remain attached when the winch is foot mounted unless a fair lead is used in which case only one tie bar should be removed When foot mounting the winch the surface must be flat within 0 5mm 020 ins and sufficiently stiff to prevent flexing A minimum of 6 4mm 0 25 ins thick steel plate should be used The thicker the plate the better the alignment between motor mounting drum and gearbox
3. 5 4 117 6662 67 60 A 11 866 1 590020 6 iussis 6 80580 ATAWASSY 1304 ASSEMBLY DRAWINGS 11 2 GUARANTEE Superwinch Limited Warranty Valid World Wide LIMITED WARRANTY Superwinch Seller warrants to the original buyer you all parts and components except wire rope to be free from defects in materials and workmanship for a period of one 1 year from the provable date of purchase Any Superwinch product which is defective will be repaired or replaced without charge to you upon compliance with these procedures The warranties set forth herein are exclusive and in lieu of all other warranties whether oral or written express or implied LIMITED WARRANTY PERFORMANCE PROCEDURE Upon discovery of a defective Superwinch product you shall mail to the Seller at his factory or any Factory Authorized Service Centre written notice of such defect and mail ship or otherwise deliver the defective Superwinch postage or shipping prepaid Repairs or replacements by Seller under this limited Warranty will normally be accomplished within fifteen 15 business days after receipt of the defective Superwinch Seller or its Authorized Agents may make reasonable charges for parts and labour for repairs not covered by this limited warranty WARRANTY AND REMEDY LIMITATIONS AND EXCLUSIONS Repair and or replacement of the
4. housing 459 18 44 TAPPED HOLES WINCH INSTALLATION NOTE ALL UNITS ARE IN EXCEPT WHERE SUFFIXED THE INCH SYMBOL WINCH INSTALLATION 04 1 CABLE INSTALLATION ROPE INSTALLATION 1 Unwind the rope by rolling it out along the ground with the tapered end nearest to the winch NEVER wind the rope straight onto the drum from a coil 2 Dis engage the Freespool 3 Insert the tapered end of the rope into the cross hole in the end of the drum and secure by tightening the setscrew 4 Re engage the Freespool 5 Carefully run the winch in the Winch In direction Keeping tension on the rope spool 5 or 6 wraps of rope neatly onto the drum 6 Apply moderate tension approx 700 kg 1500 Ib to the rope Carefully run the winch in the Winch In direc tion Ensure the layers are neatly wrapped onto the drum This will minimize damage to the lower layers of rope when a load is applied PULLING OUT THE ROPE Disengage the Freespool With a pair of gloves on pull out the rope and secure to anchor or load check that there are at least 5 turns left on the Drum Re engage the Freespool 05 1 CABLE INSTALLATION GENERAL Avoid pulling a load at more than a 15 degree angle in relation to the winch This will reduce wear and tear on the winch and the cable Note The winch is designed such that it cannot be freespooled when the drum is under load PNEUMATIC FREESPOOL OPERATION 1 Dis
5. 3Hl NIMIY SNN AH Q3ABHOV SI SIHL 13045 IHL 30 SIXV 31 OL Q3NIvHISdH 38 ISAW 9NRN3H IHL 30 33 JHL UG WWORGHdS JHL OL by 14 88 JANG 318A3SSV OL 43940 NI aie NEN 7 8 355 NAHM 9C 01 39VNVO OL 1 3 3 15 3 45 3 3 e 934 4 T33HMWHOM 3HL 1nOHLI LNO 38 41 3 5 SIHL 13 588 NO 19074 03 WWOLO OL SOO 3 3 43 01 SV SWIHS 3 1 9 483 NI 01 YO MNIVISM HIONGMIS 879 YO 809 311901 Addy Q31BW3SSv NAHM 3 OL Ol NMOHS SV ONINV3H ONY COZ XOBNSOM 3 SY SWIHS ISN NAOHS SQv3sHL 25 OL INVIV3S 1 MO INNOdWOS 133595 3113AH3H fZOLBO BC MANOS 29 DBLOS JZ AGOB 40 Ov3sHL OL INFJWAINGS YO 6 6 1 311201 Addy SHLON ATBAMASSV SUHVMNO OLS MPLH ON 5 HONIM x 8 048 81 pp ee WA eoso i r 55 1 9591 wxwas 5 11 Gens ur ET 95 11 56 68965 30 6 5 m 2680 25 21 5921 swswewm 15 82280070 95 5 588 Nid 1 65 OS 6 89
6. F YOUR WINCH 1 Itis ESSENTIAL that the winch is run in before use to achieve the performance figures stated in this manual We recommend running for approx 1 Hr at 30 of Max Oil Pressure followed by at least 350m 1200 feet of pulling the first 100m 350 feet with approx 230 450kg 500 1000 Ibs load the remainder with the load being PROGRESSIVELY increased NOTE A Installing the wire rope is not included in the running in period B Check tightness of all mounting bolts after running in 2 KEEP A TIGHTLY WOUND ROPE DRUM Do not allow the windings on the drum to become loosely wound A loosely wound spool allows a rope under load to work its way down into the layers of wire rope on the drum When this happens the lower layers become damaged and the rope may become wedged within the body of the windings To prevent this problem keep tension on the rope at all times A good practice is to rewind the rope under tension after each use 3 PREVENT KINKS BEFORE THEY OCCUR a This is the start of a kink At this time the rope should be straightened b The rope was pulled and the loop has tightened to a kink The rope is now permanently damaged c The result of kinking is that each strand pulls a different amount causing the strands under greatest tension to break and reduce load capacity of the wire rope 5 USE A SNATCH BLOCK FOR HEAVY LOADS To keep wear to a minimum use a snatch block to double line heavy lo
7. G POSSIBLE CAUSE Pump pressure output insufficient Hydraulic Hose too long or bore sizes insufficient in size Load greater than rated capacity Motor worn out Damaged freespool mechanism Damaged drum seals Seals Gaskets damaged Low Oil level Freespool not engaged CORRECTION Refer to Hydraulic Installation section Refer to Hydraulic Installation section Refer to SPECIFICATIONS page for line pull rating Replace motor See your Superwinch Distributor Replace drum seals Replace all seals gaskets Check oil level add oil if necessary Check engagement of freespool mechanism 10 1 OPERATION TROUBLESHOOTING ASSEMBLY 7081 WINCH ASSEMBLY ASSEMBLY DRAWINGS 11 1 0 IVS HLM 1 3HL OL XOBNYOM 4 539 13 WONG 45 3 51 SONI 0 vt 2 INYO 05 83 5 sz Wnua 642909 INAI 8 SNNdS INYO 1 ASSY MOLOJI3S 38 8 WNIHLIT Addy 35 3 9 NOILVOPISOT 44445 JO ASv3 SNOT 3HL NO 32V4 SNIdWVIO Sv SLOV N3HL 200 9941553138 JHL JO 3943 384 32 67 504553135 3 Z AYQI MOLOTTS IHL ALON 325 5 280438 0122135
8. Owner s Handbook HW10 HW12 HW14 HYDRAULICALLY POWERED DRUM WINCH 01 02 03 05 06 08 09 10 11 12 5 Handbook Kit Nos 7081 These instructions cover kits from 17 07 2002 INTRODUCTION GENERAL SPECIFICATION DATA INSTALLATION HYDRAULIC SYSTEM WINCH CABLE COMMISSIONING AND USE FREESPOOL RUNNING IN MAINTENANCE amp SERVICING TIPS FOR EXTENDING THE LIFE OF YOUR WINCH TROUBLESHOOTING HYDRAULIC SYSTEM OPERATION PARTS ASSEMBLY DRAWINGS MISCELLANEOUS GUARANTEE Superwinch Ltd Abbey Rise Whitchurch Road Tavistock Devon Great Britain PL19 9DR Tel 44 0 1822 614101 Fax 44 0 1822 615204 Superwinch Inc Winch Road Putnam Connecticut 06260 U S A Tel 203 928 7787 Fax 203 928 1143 britsupport superwinch com SLIPERWINCH INTRODUCTION INTRODUCTION Thank you for purchasing a Superwinch It has been designed and manufactured to provide years of trouble free operation Please read and understand this Owner s handbook before using your winch Your winch is a very powerful machine If used unsafely or improperly there is a possibility that property damage or personal injury can result We have included several unique features in the winch to minimize this possibility however your safety ultimately depends on your caution when using the prod uct Correct installation of your winch is a requirement for correct operation Pay particular
9. USION OR LIMI TATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU D Condition of Warranty Seller shall not be required to comply with its warranty duties provided herein if the defect malfunction or failure of the Superwinch was caused by damage not resulting from defective or malfunctioning components or unreasonable use by you Unreasonable use shall include but is not limited to installation or use of the Superwinch without compliance with the instruc tions contained in the Superwinch Owner s Manual for the particular model number Seller s liability under this warranty or for any loss or damage to the Superwinch product shall not exceed the cost of correcting defects in or replacing the Superwinch product and upon expiration of the warranty period all such liability shall terminate The agents dealers and employees of the Seller are not authorized to make modifications to this warranty or additional warranties binding on the Seller Accordingly additional statements whether oral or written do not constitute warranties and should not be relied upon LEGAL REMEDIES OF BUYER This Limited Warranty gives you specific legal rights and you may also have other rights which vary from State to State within the USA and from country to country You may also have implied warranty rights In the event of a problem with Limited Warranty service or performance the Buyer may be able to go to smal
10. ads Double lining reduces the work required of the gears by one half which in turn reduces wear 6 The pull required to start a load moving is often much greater than the load to keep it moving Try to AVOID STOPPING AND STARTING during a pull TIPS FOR EXTENDING THE LIFE OF YOUR WINCH 08 1 HYDRAULIC SYSTEM TROUBLESHOOTING Most hydraulic system failures follow the same pattern a gradual or sudden loss of pressure or flow with a resulting loss of motor power Any one of the systems components may be at fault By following step by step procedures the trouble can be isolated in a short time CONDITION POSSIBLE CAUSE CORRECTION SYSTEM INOPERATIVE No oil in system Fill system Check for leaks Insufficient oil in system Fill system Check for leaks Wrong oil in system Refer to manufacturers specifications amp change oil Filter dirty or clogged Drain oil and replace filter or filter element Oil line restriction Oil Clean or replace lines dirty or collapsed Air leaks in pump suction Repair or replace as necessary line Worn or dirty pump Clean repair or replace Check alignment Check for contaminated oil Drain and flush system Badly worn components Examine and test for internal or external leak age Replace faulty components Check for cause of wear Leakage Check all components particularly the relief valve for proper settings Refer to technical manuals Excessive load Check unit specificatio
11. attention to the winch installation section in this handbook Congratulations on your choice Superwinch reserve the right to alter model specifications without prior notice PLEASE KEEP THIS OWNER S HANDBOOK WITH THE WINCH These instructions are designed to assist skilled techni cians in the efficient installation of a Superwinch using the appropriate trade tools WARNINGS CAUTIONS AND NOTES These are given through these instructions in the follow ing form WARNING Procedures which must be followed precisely in order to avoid the possibility of personal injury CAUTION This calls attention to procedures which must be followed to avoid damage to components NOTE This calls attention to methods which make a job easier or gives helpful information SUPERWINCH winches are not to be used to lift support or otherwise transport personnel Any such use shall be considered to invalidate the warranty and Superwinch shall not be responsible for any claims arising from such use REPAIRS AND REPLACEMENTS Before you contact Superwinch or your nearest Dealer please have ready the following information Kit No Serial No of winch Part No required POISONOUS SUBSTANCES Many liquids and other substances used should under no circumstances be consumed and should be kept away from open wounds These substances include among others hydraulic oil SYNTHETIC RUBBER Many O ring seals flexible
12. city no brake pads to wear or delicate mechanisms to break Using a Closed Centre Spool valve will increase braking by locking both motor ports in the off position Drum fabricated steel running in plain copolymer main tenance free bearings with spring loaded brakes to pre vent over run when pulling out rope 01 1 INTRODUCTION Mounting fixing positions allow for platform in chassis mounting in either under or over winding modes INTRODUCTION 01 2 GENERAL SPECIFICATION DATA WINCH SPECIFICATION Gear Reduction Steel centred aluminium bronze wormwheel case hardened ground and polished worm Gearbox ratio 48 1 DRUM iiec Fabricated steel mounted on maintenance free bearings Braking The irreversible action of the worm and wheel provide for substantial braking action eene ines 90 mm 3 5 Model Designation H10W Part No 7081 Weight Less rope 55 kg 121 Ib Freespool Manual 02 1 GENERAL SPECIFICATION DATA HYDRAULIC SYSTEM SPECIFICATION System type canes Open system with filtered return line Relief valve Set at winch operating pressure With a supply of 60 16 U S gal min top motor r
13. d pump Damaged or worn shaft seal Loose or broken parts Control valve not centring when released CONTROL VALVE STICKY BINDING Valve linkage misaligned CONTROL VALVE LEAKS Tie bolts too tight stack valves Valve damaged Tie bolts too loose stack valves Seals damaged or worn Clean and or replace elements or lines Check relief valves etc Adjust per manual Tighten fittings Replace seals or damaged lines Return control valve to neutral when not in use Use recommended fill reservoir clean oil replace filter element Reduce engine speed Repair or replace component as necessary Clean and or replace elements or lines Clean or repair Clean dirt and mud from reservoir and components Repair or replace Replace clean or add oil as needed Check suction line and component seals for suction leaks Replace Replace clean or add oil as required Clean or replace Repair or replace Replace Check for misalignment Tighten or replace Check for spool binding Repair Repair Loosen as necessary Repair or replace Tighten as necessary Replace HYDRAULIC SYSTEM TROUBLESHOOTING 09 2 CONDITION LOW LINE PULL DRUM WILL NOT ROTATE UNDER LOAD WINCH RUNS TOO SLOW CABLE DRUM WILL NOT FREE SPOOL OIL LEAKAGE AROUND DRUM FLANGE OIL LEAKAGE AROUND MOTOR OR WORMBOX EXCESSIVE NOISE MOTOR RUNS BUT DRUM DOES NOT TURN OPERATION TROUBLESHOOTIN
14. defective Superwinch or compo nent thereof as provided herein is the exclusive remedy for the Buyer The following exclusions or limitations of warranties and limita tions of remedies shall be expressly applicable A Express warranties Seller Warrants that the Superwinch is as described in the Superwinch Owner s Manual provided herewith no other express warranty is made in respect to the Superwinch If any model or sample was shown to the Buyer such model or sample was used for illustrative purposes only and shall not be construed as a warranty that the Superwinch will conform to the sam ple or model SELLER MAKES NO EXPRESS WARRANTY WITH RESPECT TO WIRE ROPE INCORPORATED IN THE PROD UCT B Implied Warranties THE IMPLIED WARRANTY OF MERCHANTABILITY AND ALL OTHER IMPLIED WARRANTIES SHALL ONLY EXTEND FROM THE PROVABLE DATE OF PURCHASE FOR ONE 1 YEAR THE WIRE ROPE IS SOLD AS IS WITH OUT ANY IMPLIED WARRANTIES SOME STATES WITHIN THE USA DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU C Incidental and Consequential Damages SUBJECT TO SELLER S LIMITED WARRANTY OBLIGATIONS SET FORTH HERE IN SELLER SHALL NOT BE RESPONSIBLE FOR INCIDENTAL DAMAGES OF ANY KIND OR FOR CONSEQUENTIAL DAM AGES TO PROPERTY LOSS OF PROFITS AND LOSS OF USE WHICH MAY BE CAUSED BY ANY DEFECT IN OR MALFUNC TION OR FAILURE OF ENCLOSED SUPERWINCH SOME STATES WITHIN THE USA DO NOT ALLOW EXCL
15. engage the drum by operating the pneumatic con trol valve 2 Pull out the cable by hand but leave at least 5 wraps on the drum 3 Attach the load 4 Engage the drum by moving the control valve lever to the appropriate position The freespool mechanism will spring return but the drum will not engage until it has been rotated a little by hand A DO NOT ATTEMPT to pull a load until the drum is properly engaged Note The mechanism is designed such that it cannot be disengaged when the drum is under load 5 Operate the winch VEHICLE AIR SUPPLY 5 T FREESPOOL USE MANUAL FREESPOOL OPERATION 1 To disengage the freespool if engaged pull the knob and turn 90 ensuring that the knob stays OUT 2 Pull out the cable by hand but leave at least 5 wraps on the drum 3 Attach the load 4 Engage the freespool by turning the knob 90 and then rotating the drum by hand until the knob springs IN DO NOT ATTEMPT to pull a load until the drum is properly engaged 5 Operate the winch FREESPOOL USE 06 1 RUNNING IN For optimum performance all hydraulic motors need run ning in Run for approx 1 Hr at 30 of Max Oil Pressure MAINTENANCE After the first 10 hours of operation Change Gearbox oil Check tightness of mounting bolts and hydraulic connections Monthly Check oil level in gearbox Oil level should be main tained to the lower edge of the level plu
16. g hole with the winch in the upright position After 50 hours of winching or annually Change Gearbox oil Approx 3 4 Litre 0 2 U S gal Check tightness of mounting bolts and hydraulic connec tions Wormbox Gearbox The winch is delivered from the factory filled with the cor rect type and quantity of oil Change the oil in the gear box at least once a year The oil specification recom mended is BP MULTIGEAR FE 85 140 or equivalent using approx 3 4 Litre 0 2 U S gal LEVEL PLUG 07 1 RUNNING IN MAINTENANCE amp SERVICING RUNNING IN MAINTENANCE amp SERVICING SERVICING Before you contact Superwinch or your nearest Dealer for parts please have ready the following information Kit No Serial No of winch Part No required LUBRICATION CLIMATE TEMPERATURE GEARBOX OIL Arctic 13 C to 15 SAE 90 8 F to 59 F Temperate 16 C to 29 C SAE 85 140 3 F to 85 F Tropical 19 C to 43 C SAE 140 66 F to 110 F NOTE EP Extreme Pressure additives can damage copper based alloys like aluminium bronze used for the worm gear and we do not recommend their use in the worm gearbox If any doubt exists consult your lubricant suppliers technical department Freespool Handle manual freespool version lubricate regularly with light oil Drum Bearings these are self lubricating but are lubri cated with molydisulphide loaded bearing grease when assembled TIPS FOR EXTENDING THE LIFE O
17. l claims court a state Court or a federal district court in the USA or to appropriate jurisdictions outside the USA INQUIRES Any enquires regarding compliance with the warranties provided herein may be addressed in writing to Superwinch Ltd Abbey Rise Whitchurch Road Tavistock Devon PL19 9DR UK or to Superwinch Inc Winch Drive Putnam CT 06260 USA GUARANTEE 12 1 Sin fis Co Cle UE This Manuals Part is 5 001 048 Issue No 2 Superwinch Ltd Abbey Rise Whitchurch Road Tavistock Devon Great Britain PL19 9DR Tel 44 0 1822 614101 Fax 44 0 1822 615204 Superwinch Inc Winch Road Putnam Connecticut 06260 U S A Tel 203 928 7787 Fax 203 928 1143 britsupport superwinch com
18. ns for load limits Slipping or broken pump drive Repair or replace belts couplings etc Check for proper alignment or tension SYSTEM OPERATES ERRATICALLY in system Check suction side of system for leaks Repair Cold oil Allow ample warm up period Dirty or damaged components Clean or repair as necessary Restriction in filters or lines Clean and or replace elements or lines SYSTEM OPERATES SLOWLY Oil viscosity too high cold oil Allow oil to warm up before operating machine Low pump drive speed Increase engine speed check manual for recommendations Low oil level Check reservoir and add oil as necessary Air in system Check suction side for leaks Repair Badly worn pump valves etc Repair or replace as needed 09 1 HYDRAULIC SYSTEM TROUBLESHOOTING SYSTEM OPERATES SLOWLY Cont OVERHEATING OF OIL IN SYSTEM FOAMING OF OIL NOISY PUMP LEAKY PUMP OR MOTOR LOAD MOVES WITH CONTROL VALVE IN NEUTRAL Restriction in filters or lines Improper adjustments Oil leaks Oil passing through relief valve for excessive time Incorrect oil low oil dirty oil Engine running too fast Excessive component internal leakage Restriction in filters or lines Malfunctioning oil cooler Insufficient heat radiation Malfunctioning component Incorrect low or dirty oil Air leaks Low oil level incorrect oil foamy oil Suction line plugged inlet screen plugged Worn or damage
19. pipes and similar items when subjected to fire or heat can become highly corro sive Handle with seamless industrial gloves only Should skin contact occur remove contaminated clothing imme diately and obtain medical assistance without delay Meanwhile wash the affected area with copious amounts of cold water or limewater for 15 to 60 minutes RECYCLING AND THE ENVIRONMENT It is illegal to dispose of used oil in the ground down sewers or drains or into waterways Dispose of used oil through authorised waste disposal contractors If in doubt contact your local Authority for advice on disposal facilities GENERAL DESCRIPTION The winch is hydraulically driven via a hydraulic motor powered by the vehicle hydraulic system The motor dri ves the drum via a worm amp wheel reduction system The winch is reversible with power power out via a directional control valve fitted to the vehicle The standard unit is supplied with anti clockwise drum rotation on winch in when viewed from the gearbox end The winch can be used in both overwound and underwound conditions Gear reduction steel centred aluminium bronze wormwheel driven by case hardened ground and pol ished nickel steel worm running in substantial ball and roller bearing mounted in a heat treated aluminium hous ing Oil lubricated for guaranteed long life Braking self locking action of the worm and wheel assure reliable load security up to the full winch capa
20. pm The pump must be capable of delivering a pressure of 130 bar 1890 Ib in2 Heservolt sss rire Must be fitted with an oil filler device comprising strainer and air filter and a dip stick The capacity of the tank should be at least 60 litres 16 U S gal Note Don t fill the tank to the top since there must be space for expansion in the tank Suitable hydraulic oil is Castrol CRML or equivalent 150 LHM 32 68 Typical viscosity rating of 150 175 cSt at 100 C 695 816 SUS at 212 F HOS8S ia ote be etie ten e ie Should have the minimum following dimensions Pressure and flow loss is increased as hose Pump inlet line 1 1 4 1 1 2 Nominal Bore N B length increases and or bore size decreases Pressure and return lines in excess of 3 5 metres should be compensated with an increase in nominal bore size reservoir to pump Return line 1 N B control valve to reservoir Pressure hoses 1 2 N B 0 18 x 2mm control valve to load control valve Pilot line pipe 0 8 10 x 1mm Control ValVe eee ieee 4 way 3 position with spring centred open centre and built in relief valve The relief valve must be set at the winch operating pressure The valve should be mounted as close to the winch as possible MOTOT tea eet oett tete bnt ta When being used for heavy Industrial and or long periods it is a good idea to have it s case drain line connected back to the hydraulic tank
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